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Manufacturing management discipline handbook concerning contamination prevention may present principles and guidelines which can be adopted for industrial and commercial manufacturer usage. Contamination prevention program is categorized into three basic aspects: initial prevention; control of amount of unpreventable contamination; and detection and elimination of remaining contamination.
The self-contamination of spacecraft (defined as the return and deposition of outgassed molecules on its critical surfaces, either in orbit or while undergoing vacuum) is considered. Theoretical relations for the flux, density, and pressure of the emitted gas as a function of altitude, radius, and distance from the spacecraft surface are developed. The flux of the outgassed molecules that return to the emitting surface is also obtained and shown to be dependent on altitude, spacecraft dimensions, and the magnitude of outgassing. The rate of condensation and the time for the formation of a monolayer of the returning molecules can be calculated. The self-contamination of spacecraft undergoing vacuum chamber test is also theoretically examined and compared with the equivalent parameters for orbit conditions. It is concluded that, depending on the dimensions of the spacecraft relative to those of the chamber and the wall capture coefficient, ground tests conducted in the more usual space simulation chambers can provide returning fluxes and self-contamination comparable to those occurring in space up to an altitude of about 400 km. For higher altitudes and return fluxes less than 0.001 of those emitted, the chamber test can produce a greater contamination. In this case, the ground results can be related to those obtained in space, provided that the wall capture coefficient is known or if the ratio of returned to emitted flux at the spacecraft surface is measured.
The contamination character of selected materials used in space technology testing is presented. Many of these materials contain components that become volatile in a space environment. Most previous data were limited to weight loss or vapor pressure. However, these parameters are not necessarily a direct measure of the contamination character of these materials. Selected materials were exposed to a thermal-vacuum environment, and the degree of contamination was measured by collecting the outgases from these materials on a cold test mirror surface. The degradation of reflectivity of the mirror was measured over a spectral range from 1100 A to 2.5 microns. Half the mirror's surface was also exposed to UV irradiation to determine its effects on the contaminative character of the depositing outgases. The amount of deposit per unit area was measured by microbalances mounted near the mirror; the sensor of one microbalance was UV irradiated. A quadrupole mass spectrometer was used to determine the composition of the outgases.
The complex problem why large space simulation chambers do not realize the true ultimate vacuum was investigated. Some contaminating factors affecting diffusion pump performance have been identified and some advances in vacuum/distillation/fractionation technology have been achieved which resulted in a two decade or more lower ultimate pressure. Data are presented to show the overall or individual contaminating effect of commonly used phthalate ester plasticizers of 390 to 530 molecular weight on diffusion pump performance. Methods for removing contaminants from diffusion pump silicone oil during operation and reclaiming contaminated oil by high vacuum molecular distillation are described.
Examples of contamination of sensors from various sources during space missions are presented. Design precautions to provide access to optical surfaces and venting of outgassing products are recommended as methods for coping with contamination. The effects of the sensor materials on sensor contamination are analyzed. Actions to be taken during transportation, storage, and testing of sensors to avoid contamination are discussed.
The potential gain in the reliability of reusable long-term mission vehicles through the minimization of component damage due to the ingestion of particulate contamination by feed system components has been recognized by the NASA-LeRC and MDAC, and a program to investigate these problems has been completed. This investigation covered the determination of the cycle life of a typical 2-in. poppet type of shutoff valve in an uncontaminated GH2 environment and then compared this component performance with simulated operation with GN2 and LN2 containing controlled amounts of AL2O2 contaminant particles. The original valve design was tested for contamination damage tolerance characteristics under full flow and cyclic operating conditions, redesigned to improve the damage tolerance to contaminants and then retested. A second method of approach to damage tolerance control was investigated through the evaluation of various types of particulate separation devices. The study included various types of dynamic separators but did not cover conventional filter assemblies.
Results of a study on the feasibility of removing contaminant films from optical surfaces in vacuum, using an oxygen plasma, are discussed. Contaminant films were deposited onto optical surfaces from butadiene and methane gases at a pressure of about 4 torr in the presence of ultraviolet radiation. Optical surfaces evaluated included ultraviolet-reflecting mirrors, gratings, quartz disks, and spacecraft thermal control surfaces. In general, it was found that contaminants could be removed successfully from surfaces using an oxygen plasma. Exceptions were the white-paint thermal control surfaces, which, when contaminated, degraded further during exposure to the oxygen plasma.
The feasibility of monitoring volatile contaminants in a large space simulation chamber using techniques of internal reflection spectroscopy was demonstrated analytically and experimentally. The infrared spectral region was selected as the operational spectral range in order to provide unique identification of the contaminants along with sufficient sensitivity to detect trace contaminant concentrations. It was determined theoretically that a monolayer of the contaminants could be detected and identified using optimized experimental procedures. This ability was verified experimentally. Procedures were developed to correct the attenuated total reflectance spectra for thick sample distortion. However, by using two different element designs the need for such correction can be avoided.
A study was conducted to determine and quantify the expected particulate and molecular on-orbit contaminant environment for selected space shuttle payloads as a result of major shuttle orbiter contamination sources. Individual payload susceptibilities to contamination are reviewed. The risk of payload degradation is identified and preliminary recommendations are provided concerning the limiting factors which may depend on operational activities associated with the payload/orbiter interface or upon independent payload functional activities. A basic computer model of the space shuttle orbiter which includes a representative payload configuration is developed. The major orbiter contamination sources, locations, and flux characteristics based upon available data have been defined and modeled.
Contaminant generation studies were conducted at the component level using two different methods, radioactive tracer technique and gravimetric analysis test procedure. Both of these were reduced to practice during this program. In the first of these methods, radioactively tagged components typical of those used in spacecraft were studied to determine their contaminant generation characteristics under simulated operating conditions. Because the purpose of the work was: (1) to determine the types and quantities of contaminants generated; and (2) to evaluate improved monitoring and detection schemes, no attempt was made to evaluate or qualify specific components. The components used in this test program were therefore not flight hardware items. Some of them had been used in previous tests; some were obsolete; one was an experimental device. In addition to the component tests, various materials of interest to contaminant and filtration studies were irradiated and evaluated for use as autotracer materials. These included test dusts, plastics, valve seat materials, and bearing cage materials.
This study is to identify and quantify the expected molecular and particulate on orbit contaminant environment for selected shuttle payloads as a result of major spacelab and shuttle orbiter contaminant sources. This investigation reviews individual payload susceptibilities to contamination, identifies the combined induced environment, identifies the risk of spacelab/payload critical surface(s) degradation, and provides preliminary contamination recommendations. It also establishes limiting factors which may depend upon operational activities associated with the payloads, spacelab, and the shuttle orbiter interface or upon independent payload functional activities.
A system for removing contaminants from spacecraft atmospheres was studied, which utilizes catalyst-impregnated activated carbon followed by in-situ regeneration by low-temperature catalytic oxidation of the adsorbed contaminants. Platinum was deposited on activated carbon by liquid phase impregnation with chloroplatinic acid, followed by drying and high-temperature reduction. Results were obtained for the seven selected spacecraft contaminants by means of three experimental test systems. The results indicate that the contaminants could be removed by oxidation with very little loss in adsorptive capacity. The advantages of a catalyst-impregnated carbon for oxidative regeneration are found to be significant enough to warrent its use.
The complex problem of why large space simulation chambers do not realize true ultimate vacuum was investigated. Some contaminating factors affecting diffusion pump performance were identified, and some advances in vacuum distillation-fractionation technology were achieved which resulted in a two-decade-or-more lower ultimate pressure. Data are presented to show the overall or individual contaminating effects of commonly used phthalate ester plasticizers of 390 to 530 molecular weight on diffusion pump performance. Methods for removing contaminants from diffusion pump silicone oil during operation and for reclaiming contaminated oil by high-vacuum molecular distillation are described. Conceptual self-cleansing designs and operating procedures are proposed for modifying large diffusion pumps into high-efficiency distillation devices. The potential exists for application of these technological advancements to other disciplines, such as medicine, biomedical materials, metallurgy, refining, and chemical (diffusion-enrichment) processing.
The development and use is described of a basic contamination mathematical model of the shuttle orbiter which incorporates specific shuttle orbiter configurations and contamination sources. These configurations and sources were evaluated with respect to known shuttle orbiter operational surface characteristics and specific lines-of-sight which encompass the majority of viewing requirements for shuttle payloads. The results of these evaluations are presented as summary tables for each major source. In addition, contamination minimization studies were conducted and recommendations are made, where applicable, to support the shuttle orbiter design and operational planning for those sources which were identified to present a significant contamination threat.
An Outer Planets Probe which retains the charred heatshield during atmospheric descent must deploy a sampling tube through the heatshield to extract atmospheric samples for analysis. Once the sampling tube is deployed, the atmospheric samples ingested must be free of contaminant gases generated by the heatshield. Outgassing products such as methane and water vapor are present in planetary atmospheres and hence, ingestion of such species would result in gas analyzer measurement uncertainties. This paper evaluates the potential for, and design impact of, the extracted atmospheric samples being contaminated by heatshield outgassing products. Flight trajectory data for Jupiter, Saturn and Uranus entries are analyzed to define the conditions resulting in the greatest potential for outgassing products being ingested into the probe's sampling system. An experimental program is defined and described which simulates the key flow field features for a planetary flight in a ground-based test facility. The primary parameters varied in the test include: sampling tube length, injectant mass flow rate and angle of attack. Measured contaminant levels predict the critical sampling tube length for contamination avoidance. Thus, the study demonstrates the compatibility of a retained heatshield concept and high quality atmospheric trace species measurements.
A trace contaminant control system was designed, fabricated, and evaluated to determine suitability of the system concept to future manned spacecraft. Two different models were considered. The load model initially required by the contract was based on the Space Station Prototype (SSP) general specifications SVSK HS4655, reflecting a change from a 9 man crew to a 6 man crew of the model developed in previous phases of this effort. Trade studies and a system preliminary design were accomplished based on this contaminant load, including computer analyses to define the optimum system configuration in terms of component arrangements, flow rates and component sizing. At the completion of the preliminary design effort a revised contaminant load model was developed for the SSP. Additional analyses were then conducted to define the impact of this new contaminant load model on the system configuration. A full scale foam-core mock-up with the appropriate SSP system interfaces was also fabricated.
Alternative techniques for the regeneration of carbon contaminated with various spacecraft contaminants were evaluated. Four different modes of regeneration were evaluated: (1) thermal desorption via vacuum, (2) thermal desorption via nitrogen purge, (3) in-situ catalytic oxidation of adsorbed contaminants, and (4) in-situ non-catalytic oxidation of adsorbed contaminants.
The limits of the infrared region of the electromagnetic spectrum are discussed, together with an explanation of some of the shortcomings of obtaining data in this range. Similarities and differences in the interest taken by the chemist/spectroscopist and the space/spectroscopist in the IR spectrum are discussed. The chemist uses IR spectra to identify materials and contaminants associated with spacecraft fabrication and testing. The space scientist, using IR spectrometry, can determine atmospheric conditions around planets, stars, and galaxies. He could also determine the temperature profile of the Earth's atmosphere at different altitudes, or even the temperature profile of the Sun. The importance of detecting contamination of spacecraft and the possible results of not taking corrective action are explored. All space experiments contain some contaminants, to a lesser or greater degree; the responsible personnel involved must determine the level of toleration. A collection of IR spectra of known spacecraft contaminants is presented as a guide for cognizant scientists and engineers.